Power switch indicator and method of operating the same

ABSTRACT

A cleaning system comprising a motor, an indicator, a battery configured to selectively supply power to the motor and the indicator, and a power switch having an on position and an off position. The cleaning system further comprises a controller having an electronic processor. The controller is configured to activate the indicator when the power switch is in the on position and power is flowing from the battery to the motor and pulse the indicator when the power switch is in the on position and power flow from the battery to the motor is terminated.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 62/925,570, filed Oct. 24, 2019, the entire contents of which are hereby incorporated by reference herein.

FIELD

Embodiments relate to tools, such as but not limited to, cleaning systems or cleaners.

SUMMARY

Tools, such as cleaners, may include one or more motors which are powered by a rechargeable battery pack. When a power switch of the tool is turned on, power flows from the rechargeable battery pack to the motor. Upon the occurrence of an event, power flow from the rechargeable battery pack to the motor may be terminated; however, a nominal amount of power may still be supplied to the tool when the power switch is turned on. This may cause the voltage of the rechargeable battery pack to decrease, although power is not flowing from the rechargeable battery pack to the motor.

Some cleaners (or battery packs) may include sensors (for example, current sensors, voltage sensors, etc.), along with discharge switches (for example, discharge field effect transistors (FETs)), configured to electrically disconnect the battery pack from the cleaner before the voltage of the battery pack falls below a predetermined threshold. However, such discharge switches may not only add to the cost of cleaners, but furthermore, only protect from over-discharge and do not conserve battery voltage.

Thus, one embodiment provides a cleaning system including a motor, an indicator, a battery configured to selectively supply power to the motor and the indicator, and a power switch having an on position and an off position. The cleaning system further includes a controller having an electronic processor. The controller is configured to activate the indicator when the power switch is in the on position and power is flowing from the battery to the motor and pulse the indicator when the power switch is in the on position and power flow from the battery to the motor is terminated.

Another embodiment provides a method for indicating a state of a cleaning system to a user. The method includes activating, via a controller having an electronic processor, an indicator of the cleaning system when a power switch of the cleaning system is in an on position and power is flowing from a battery of the cleaning system to a motor of the cleaning system. The method further includes pulsing, via the controller, pulsing the indicator when the power switch is in the on position and power flow from the battery to the motor is terminated.

Other aspects of the application will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a cleaning system according to some embodiments.

FIG. 2 is a side view of the cleaning system of FIG. 1 according to some embodiments.

FIG. 3 is an enlarged view of a handle assembly of the cleaning system of FIG. 1 according to some embodiments.

FIG. 4 is an enlarged frontal view of a head of the cleaning system of FIG. 1 according to some embodiments.

FIG. 5 is an enlarged perspective view of a head of the cleaning system of FIG. 1 according to some embodiments.

FIG. 6 is a block diagram of a control system of the cleaning system of FIG. 1 according to some embodiments.

FIG. 7 is a flowchart illustrating the process or operation of the cleaning system of FIG. 1 according to some embodiments.

FIG. 8 is a flowchart illustrating the process or operation of the cleaning system of FIG. 1 according to other embodiments.

FIG. 9 is a flowchart illustrating the process or operation of the cleaning system of FIG. 1 according to other embodiments.

FIG. 10 is a flowchart illustrating the process or operation of the cleaning system of FIG. 1 according to other embodiments.

Before any embodiments of the application are explained in detail, it is to be understood that the application is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The application is capable of other embodiments and of being practiced or of being carried out in various ways.

DETAILED DESCRIPTION

FIGS. 1-5 illustrate a cleaning system 100 according to some embodiments. The cleaning system 100 may be configured to clean a surface (for example, a floor such as a hardwood floor, a carpeted floor, upholstery, etc.). Although illustrated as an upright vacuum cleaner, in other embodiments, the cleaning system 100 may be another type of vacuum, such as but not limited to, a handheld vacuum cleaner or a stick vacuum cleaner.

The cleaning system 100 may include a spine, or body structure, 110. The spine 110 may support a handle assembly of the cleaning system 100, the handle assembly 120 having a grip 122 for a user to grasp. The handle assembly 120 may further include a user-interface 124. As illustrated, in some embodiments, user-interface 124 includes a power switch 125 having an on position and an off position. The power switch 125 may be operated by a user. FIG. 3 illustrates an enlarged view of the handle assembly 120. As illustrated in FIG. 3, in some embodiments the power switch 125 may be a slide switch, operable to be moved back and forth between the on position and the off position by a user. In other embodiments, the power switch 125 may be, but not limited to, a push button switch or a toggle switch.

The spine 110 may further support a canister 130. In some embodiments, the canister 130 may include a separator configured to remove dirt particles from an airflow drawn into the system 100 that is then collected by canister 130. The separator may be a cyclonic separator, a filter bag, and/or another separator. The canister 130 may further include a suction motor 134 coupled to a suction source, such as but not limited to, an impeller or fan assembly driven by the suction motor 134. The spine 110 may further support a battery pack 140 being configured to supply power to the cleaning system 100 for operation. In some embodiments, the battery pack 140 is contained within the canister 130. However, in other embodiments, the battery pack 140 is releasably coupled to a battery receptacle of the system 100.

The spine 110 may be coupled to a base assembly 150. The base assembly 150 may include a housing 152. The base assembly 150 may further include a brush roll 153 powered via a brush roll motor 154 contained within the housing 152. Air and/or debris is drawn through a nozzle opening, or inlet, 157 in the housing 152 via the suction motor 134.

The cleaning system 100 may further include an indicator 160 (for example, a headlight positioned on the housing 152 as illustrated in FIGS. 1, 4, and 5) configured to display conditions of, or information associated with, the cleaning system 100. The indicator 160 may be further configured to alert a user to a change in the condition of the cleaning system 100. In some embodiments, the indicator 160 may include one or more lights (for example, light emitting diodes), varying in color and orientation. In some embodiments, the indicator 160 may include elements to convey information to a user through audible or tactile outputs (for example, a speaker and/or vibration motor, for example, located in the handle assembly 120).

FIG. 6 is a block diagram of a control system 200 of the cleaning system 100 according to some embodiments. The control system includes a controller 205. The controller 205 is electrically and/or communicatively connected to a variety of modules or components of the cleaning system 100. For example, the controller 205 is connected to the user-interface 124, the suction motor 134, the brush roll motor 154, a power supply 210, and one or more sensors 220.

In some embodiments, the controller 205 includes a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within the controller 205 and/or the cleaning system 100. For example, the controller 205 includes, among other things, an electronic processor 230 (for example, a microprocessor or another suitable programmable device) and a memory 235.

The memory 235 includes, for example, a program storage area and a data storage area. The program storage area and the data storage area can include combinations of different types of memory, such as read-only memory (ROM) and random access memory (RAM). Various non-transitory computer readable media, for example, magnetic, optical, physical, or electronic memory may be used. The electronic processor 230 is communicatively coupled to the memory 235 and executes software instructions that are stored in the memory 235, or stored in another non-transitory computer readable medium such as another memory or a disc. The software may include one or more applications, program data, filters, rules, one or more program modules, and other executable instructions.

Power supply 210 is configured to supply power to the controller 205 and/or other components of the cleaning system 100. As illustrated, in some embodiments, the power supply 210 receives power from the battery pack 140 and provides regulated power to the controller 205 and/or other components of the cleaning system 100. In some embodiments, the power supply 210 may include DC-DC converters, AC-DC converters, DC-AC converters, and/or AC-AC converters. In other embodiments, the power supply 210 may receive power from an AC power source (for example, an AC power outlet).

In some embodiments, the battery pack 140 includes a battery pack housing 142. The battery pack housing formed of plastic or a similar material. The battery pack 140 may further include a battery pack interface for physically and/or electrically coupling the battery pack 140 to a battery receptacle. In some embodiments, the battery pack 140 may further include a battery controller and one or more battery cells. The battery controller may be configured to monitor and/or control various aspects of the battery pack and/or battery cells.

The one or more battery cells may be rechargeable battery cells having a lithium-ion chemistry. In some embodiments, the one or more battery cells are connected in a series-type configuration. However, in other embodiments, the one or more battery cells are connected in a different configuration, for example, a series-type configuration and/or a parallel-type configuration.

The user-interface 124 is configured to receive input from a user and/or output information to the user concerning the cleaning system 100. Although illustrated as including power switch 125, in other embodiments, the user-interface 124 includes, in addition to or in lieu of power switch 125, a display (for example, a primary display, a secondary display, etc.) and/or input devices (for example, touch-screen displays, a plurality of knobs, dials, switches, buttons, etc.). The display may be, for example, a liquid crystal display (“LCD”), a light-emitting diode (“LED”) display, an organic LED (“OLED”) display, an electroluminescent display (“ELD”), a surface-conduction electron-emitter display (“SED”), a field emission display (“FED”), a thin-film transistor (“TFT”) LCD, etc.

The one or more sensors 220 are configured to sense one or more characteristics of the cleaning system 100. In some embodiments, the one or more sensors 220 include a voltage sensor configured to monitor the voltage level of the battery pack 140. In some embodiments, the one or more sensors 220 include one or more current sensors configured to monitor the current flowing through the suction motor 134 and/or the brush roll motor 154. In some embodiments, the one or more sensors 220 includes a sensor configured to detect proximity of the cleaning system 100 to surrounding objects. In some embodiments, the one or more sensors 220 includes an air flow sensor configured to monitor an airflow between the inlet 157 and the canister 130. In some embodiments, the one or more sensors 220 includes a pressure sensor configured to determine whether or not the canister 130 is at capacity. In some embodiments, the one or more sensors 220 include a position sensor configured to detect a position of the spine 110 with respect to the base assembly 150.

In one exemplary embodiment of the operation of cleaning system 100, a user operates the power switch 125 to be in the on position, activating cleaning system 100. In such an embodiment, when power switch 125 is in the on position, power is supplied to the suction motor 134 from battery pack 140, and suction motor 134 is activated. In such an embodiment, when power is supplied to the suction motor 134, suction motor 134 acts as an electrical load on the battery pack 140. When power switch 125 is operated to be in the off position, power flow from the battery pack 140 to the suction motor 134 is terminated. However, in some instances, when power switch 125 is in the on position, power flow from the battery pack 140 to the suction motor 134 is terminated upon an occurrence of an event. Even after power flow from the battery pack 140 to the suction motor 134 is terminated, a nominal amount of power may still be supplied from the battery pack 140 to the cleaning system 100 when the power switch 125 is in the on position.

In some embodiments, the event is an error condition that occurs when the position sensor senses the handle assembly 120 and/or spine 110 of the cleaning system 100 entering an upright position when the power switch 125 is in the on position. In some embodiments, the event is an error condition that occurs when the current sensor senses a change in current associated with a brush roll motor 154 stall when the power switch 125 is in the on position. In some embodiments, the event is an error condition that occurs when the airflow sensor senses a blockage in airflow from the nozzle opening in the housing 152 to the canister 130 when the power switch 125 is in the on position. In some embodiments, the event is an error condition that occurs when the pressure sensor senses that the canister 130 is at capacity when the power switch 125 is in the on position.

In some embodiments, the voltage sensor monitors the voltage level of the battery pack 140. In such an embodiment, the event may be an error condition that occurs when the voltage sensor senses the battery pack 140 voltage level dropping below a voltage threshold level (for example, approximately 12 volts) when the power switch 125 is in the on positon.

In some embodiments, the current sensor monitors the current supplied to the suction motor 134 and/or brush roll motor 154. The event may be an error condition that occurs when the current sensor senses the current supplied to the suction motor 134 and/or brush roll motor crossing a current threshold level (for example, approximately 7 amps).

In some embodiments, the controller 205 may be configured to activate the indicator 160 when the power switch 125 is in the on position and power flow from the battery pack 140 to the suction motor 134 (and/or the brush roll motor 154) is terminated. The controller 205 may be further configured to pulse the indicator 160 upon activation. The controller 205 may be further configured to terminate power flow from the battery pack 140 to the indicator 160 when the voltage sensor 220 senses the battery pack 140 voltage level dropping below a second voltage threshold level. The controller 205 may be further configured to terminate power flow from the battery pack 140 to the indicator 160 when the power switch 125 is operated to be in the off position.

In some embodiments, the controller 205 may be configured to activate the indicator 160 when the power switch 125 is in the on position and power flow from the battery pack 140 to the suction motor 134 (and/or the brush roll motor 154) is terminated. The controller 205 may be further configured to pulse the indicator 160 upon activation. The indicator may be pulsed for a predetermined amount of time (for example, 30 seconds). After the predetermined amount of time is elapsed, the controller 205 may be configured to stop pulsing the indicator 160. The controller 205 may be further configured to terminate power flow from the battery pack 140 to the indicator 160 when the voltage sensor 220 senses the battery pack 140 voltage level dropping below a second voltage threshold level. The controller 205 may be further configured to terminate power flow from the battery pack 140 to the indicator 160 when the power switch 125 is operated to be in the off position.

In some embodiments, the controller 205 may be configured to dim the indicator 160 light when the power switch 125 is in the on position and power flow from the battery pack 140 to the suction motor 134 is terminated. The controller 205 may be further configured to change a color of the indicator 160 light when the power switch 125 is in the on position and power flow from the battery pack 140 to the suction motor 134 has been terminated.

In some embodiments, wherein the indicator 160 includes a speaker, the controller 205 may be configured to activate the speaker when the power switch 125 is in the on position and power flow from the battery pack 140 to the suction motor 134 has been terminated. In some embodiments, wherein the indicator 160 includes a vibration motor, the controller 205 may be configured to activate the vibration motor when the power switch 125 is in the on position and power flow from the battery pack 140 to the suction motor 134 has been terminated.

FIG. 7 is a flowchart illustrating a process, or operation, 300 for indicating the condition of the cleaning system 100 according to one embodiment. It should be understood that additional steps may be added and not all of the steps may be required. The cleaning system 100 is initially in operation (block 305). Power flow from the battery pack 140 to the suction motor 134 is terminated (block 310). As discussed above, power flow from the battery pack 140 to the suction motor 134 may be terminated as a result of one or more events. Controller 205 determines if the power switch 125 is in the on position (315) after power from has been terminated. If the power switch 125 is in the on position, the indicator 160 is activated (block 320). If the power switch 125 is not in the on position, the indicator 160 is not activated (block 325).

FIG. 8 is a flowchart illustrating an alternative process, or operation, 400 for indicating the condition of the cleaning system 100 according to one embodiment. It should be understood that the order of the steps disclosed in process 400 could vary. Furthermore, additional steps may be added and not all of the steps may be required. A user operates the power switch 125 to be in the ON position (block 405). Power flows from the battery pack 140 to the suction motor 134 (block 410). An event occurs (block 415). Power flow from the battery pack 140 to the suction motor 134 is terminated (block 420). Controller 205 determines if the power switch 125 is maintained in the ON position (block 425). When the power switch 125 is in the OFF position, the indicator 160 is not activated (block 430). When the power switch 125 is in the ON position, the indicator 160 is activated (block 435). In some embodiments, upon activation of the indicator 160, the indicator 160 goes from a constant on state to a pulsed state.

FIG. 9 is a flowchart illustrating an alternative process, or operation, 500 for indicating the condition of the cleaning system 100. It should be understood that the order of the steps disclosed in process 500 could vary. Furthermore, additional steps may be added and not all of the steps may be required. The cleaning system is initially in operation (block 505). The voltage level of the battery pack 140 is sensed (block 510). Controller 205 determines if voltage level of the battery pack 140 drops below a voltage threshold level (block 515). When the voltage level of the battery pack 140 is above the voltage threshold level, process 500 cycles back to step 505.

When the voltage level of battery pack 140 drops below the voltage threshold level, power flow from the battery pack 140 to the suction motor 134 is terminated (block 520). Controller 205 determines if the power switch 125 is still in the on position (block 525). When the power switch 125 is in the OFF position, the indicator 160 is not activated (block 530). When the power switch 125 is in the ON position, the indicator 160 is activated (block 535) (for example, by pulsing).

The voltage level of the battery pack is once again sensed (block 540). Controller 205 determines if voltage level of the battery pack 140 drops below a second voltage threshold level (block 545). When the voltage level of the battery pack 140 is above the second voltage threshold level, process 500 cycles back to block 540. When the voltage level of battery pack 140 drops below the second voltage threshold level, power flow from the battery pack 140 to the indicator 160 is terminated (block 550).

FIG. 10 is a flowchart is a flowchart illustrating an alternative process, or operation, 600 for indicating the condition of the cleaning system 100. It should be understood that the order of the steps disclosed in process 600 could vary. Furthermore, additional steps may be added and not all of the steps may be required. A user operates the power switch 125 to be in the ON position (block 605). Power flows from the battery pack 140 to the suction motor 134 (block 610). An event occurs (block 615). Power flow from the battery pack 140 to the suction motor 134 is terminated (block 620). Controller 205 determines if the power switch 125 is maintained in the ON position (block 625). When the power switch 125 is in the OFF position, the indicator 160 is not activated (block 630). When the power switch 125 is in the ON position, the indicator 160 is activated (block 635).

Upon activation, the indicator 160 is pulsed for approximately 30 seconds (block 640). After 30 seconds, the voltage level of the battery pack 140 is sensed (block 644). Controller 205 determines if voltage level of the battery pack 140 drops below a voltage threshold level (block 650). When the voltage level of the battery pack 140 is above the voltage threshold level, process 600 cycles back to step 645. When the voltage level of battery pack 140 drops below the voltage threshold level, power flow from the battery pack 140 to the indicator 160 is terminated (block 655).

The power switch 125 in the on position enables flow of current from the battery pack 140. As discussed above, even after power flow from the battery pack 140 to the suction motor 134 is terminated, a nominal amount of power may still be supplied from the battery pack 140 to the cleaner 100 when the power switch 125 is in the on position, primarily due to power consumption by the controller 205 and other components. We have found that even a nominal amount of power may drain certain battery packs to lower charge levels than desired. Therefore, it is beneficial for a user to turn the power switch 125 to the off position when the controller 205 turns off the suction motor 134 upon the occurrence of an event. By turning the power switch 125 to the off position, the flow of current from the battery will stop and the battery pack will not further drain. However, when the controller 205 turns the suction motor off, the operating sound of the suction motor stops and the user can incorrectly believe that the cleaner has turned off, even though the power switch 125 is in the on position. The present indicator 160 is configured to provide a noticeable indication for a period that the user can see and understand that the power switch 125 is still on. The indication, such as a flashing light, or flashing of the cleaner's headlights, stops when the user turns the power switch to the off position. Also, if the user fails to turn the power switch to the off position, the controller may discontinue the indication if the charge level of the battery pack reaches a predetermined low level, to slow the power drain from the battery.

Thus, the application provides, among other things, a cleaning system having an indicator. Various features and advantages of the application are set forth in the following claims. 

1. A cleaning system comprising: a motor; an indicator; a battery configured to selectively supply power to the motor and the indicator; a power switch having an on position and an off position; and a controller having an electronic processor, the controller configured to: activate the indicator when the power switch is in the on position and power flow from the battery to the motor has been terminated.
 2. The cleaning system of claim 1, wherein the motor is at least one selected from a group consisting of a suction motor and a brush roll motor.
 3. The cleaning system of claim 1, wherein power flow from the battery to the motor is terminated upon an occurrence of an event.
 4. The cleaning system of claim 3, wherein the cleaning system further comprises a handle; and wherein the event is an error condition that occurs when the handle of the cleaning system enters an upright position.
 5. The cleaning system of claim 3, wherein the event is an error condition that occurs when the brush roll motor is stalled.
 6. The cleaning system of claim 3, wherein the event is a condition that occurs when a voltage level of the battery drops below a voltage threshold level.
 7. The cleaning system of claim 1, wherein the controller terminates power flow from the battery to the indicator when the voltage level of the battery drops below a second voltage threshold level.
 8. The cleaning system of claim 1, wherein the controller terminates power flow from the battery to the indicator when the power switch is changed to the off position.
 9. The cleaning system of claim 1, wherein the indicator is a light.
 10. The cleaning system of claim 9, wherein the controller pulses the light upon activation.
 11. The cleaning system of claim 9, wherein the controller dims the light upon activation.
 12. The cleaning system of claim 9, wherein the controller changes a color of the light upon activation.
 13. The cleaning system of claim 1, wherein the indicator is a speaker.
 14. The cleaning system of claim 13, wherein the controller pulses the indicator speaker upon activation.
 15. A method for indicating a state of a cleaning system to a user, the method comprising: determining, via a controller having an electronic processor, a position of a power switch; determining, via the controller, a flow of electrical energy from a battery to a motor of the cleaning system; and activating, via the controller, an indicator when: the power switch is in an on position, and the flow of electrical energy from the battery to the motor has been terminated.
 16. The method of claim 15, wherein the motor is at least one selected from a group consisting of a suction motor and a brush roll motor.
 17. The method of claim 15, further comprising: terminating, via a controller, power flow from the battery to the motor upon an occurrence of an event.
 18. The method of claim 17, further comprising: terminating, via a controller, power flow from the battery to the motor upon the occurrence of the event; and wherein the event is an error condition that occurs when a handle of the cleaning system enters an upright position.
 19. The method of claim 17, further comprising: terminating, via a controller, power flow from the battery to the motor upon the occurrence of the event; and wherein the event is an error condition that occurs when the brush roll motor is stalled.
 20. The method of claim 17, further comprising: terminating, via a controller, power flow from the battery to the motor upon the occurrence of the event; and wherein the event is a condition that occurs when a voltage level of the battery drops below a voltage threshold level. 21.-28. (canceled) 